QC Conveyors FLEXTRAC Series User manual

Model Number __________________________
Serial Number __________________________
Date of Install __________________________
For ease of reference please fill out your conveyor’s specific information above
FLEXTRAC SERIES MANUAL
Installation & Maintenance
MAN-FT-2002
4057 Clough Woods Drive
Batavia, OH 45103 USA
[phone]
qcconveyors.com
CONTENTS
Introduction page 2
Tools & Fasteners page 3
Assembly page 4
Plastic Belt Installation page 17
Start up & Testing page 18
Introduction to Maintenance page 20
Conveyor Chains page 26

2 | Installation Site Preparation — Introduction to Installation | Flextrac Series
Installation Site Preparation INTRODUCTION TO INSTALLATION

The purpose of this manual is to help the end user to assemble a Flextrac Series conveyor system. Every chapter includes detailed
instructions and photos showing how to assemble each component. Most photos in this manual include parts from MM3 conveyor
system, but all instructions are applicable to MS2, ML2, and MX2 conveyor system unless otherwise specied or noted.
Assembly Planning
Fully understand the assembly drawing.
Ensure the necessary tools are available.
Ensure all the parts and materials included on parts list are available.
Ensure necessary space for conveyor installation is available.
Ensure the oor is even so the feet can be properly attached to the oor.
Assembly Checklist
Cut all beams to desired length.
Connect all feet and structural beams.
Mount conveyor beam support brackets.
Mount slide rail onto the conveyor beam.
Assemble conveyor beams and mount them onto the support structure.
Mount drive and idler unit at the end of the conveyor.
Check for obstruction of the conveyor with a short piece of chain.
Assemble and mount necessary chain onto the conveyor.
Mount guide rail and other accessories onto the conveyor.
Read the nal preparations at the end of this manual.

qcconveyors.com | Tools — Tools & Fasteners | 3
Tools
Hand Tools
Wrench
Slide rail cutter
Set of metric Allen wrenches
Counter sunk bit
Measuring tape
Chain inserting / removing tools
Drill xtures for slide rail
Riveting Tool
Files
M8 ratcheting socket wrench
Screwdriver
Pliers
Knife (for cutting o plastic screw head or burr of slide rail)
Soft head hammer
Clamping tools (for chain installation and dismantling)
Level
Power Tools
Hand Drill
Drill bit
TOOLS & FASTENERS 
To assemble a Flextrac Series conveyor, you may need tools listed below.
Fasteners 
Standard Fasteners
M8 = Washer, Counter sunk screw,
Cap screw, Nut, Lock Nut
M6 = Washer, Counter sunk screw,
Cap screw, Nut, Lock Nut
Square Nut
Slide into T-slot of Flextrac Series
conveyor and support beams for
attaching accessories
Connecting Strip
Use for joining conveyor beams
end-to-end; use Allen key and set
screws to tighten the connecting
strip to the beam.
T-bolt
Use when attaching support
brackets, guide rails and
drip tray to the conveyor beam

4 | Components — Assembly | Flextrac Series
Components
Cutting Flextrac Series Beam
ASSEMBLY


If you have ordered 3m beams, they will need to be cut into suitable lengths before assembly. Study your drawing
to determine the beam lengths required before cutting.
Saw requirements: Use miter saw for aluminum prole cutting at a high speed for nice, clean cuts. The saw should have the
ability to cut the largest prole in one single cutting action.
Working site: You should use a special area for cutting beams in order to keep the assembly area clean.
Quality of cut: If burrs are evident, they must be removed prior to assembly. Make sure the cut is straight for proper assembly
Safety: All safety precautions issued by the cutting saw manufacturer should be followed at all times.
The basic Flextrac Series conveyor structure consists of ve component groups:
Conveyor beams, Drive Units, Idler Units and Bends
Conveyor Guide
Structure System
Conveyor Accessories
Safety

qcconveyors.com | Assembly — Foot Installation | 5
Foot Cap Installation 
Foot InstallationASSEMBLY 
The rst step in the assembly process is to assemble the support structure, which consists of feet, support beams and beam support
brackets. Most conveyor support designs are based on vertical support beams, combined if necessary, with horizontal support beams.
There are also a number of dierent feet and beam support brackets, so check which ones are suitable to use in your application.
Insert hex head screws
and washers into the
holes on the side of the foot.
Use the screws to fasten foot
connecting strips or square nut to
the inner side of the foot.
1
Thread the holes using
6mm tap. Attach the
support bracket to the beam by
inserting 4 socket head cap screws
into the holes on the support
bracket. Tighten the screws using
an Allen key.
1
Raise the beam from
the bottom of the foot
approximately 30mm, to allow
for height adjustment later in the
assembly.
3
Tighten the nut using the
wrench.
3
Slide the connecting
strips or square nuts into
the structural beam T-slots.
2
Screw the foot cap onto
the support bracket.
2
Tighten the screws using
a wrench.
4

6 | Structural Beam Installation — Assembly | Flextrac Series
Structural Beam Installation
Angle Bracket Installation Connecting Plate Installation
ASSEMBLY

Mounting Conveyor Beam Support Bracket

There are various types of support brackets; each is connected to the structural beam in dierent ways.
Insert the required
number of square nuts
into the structural beam T-slot.
Mount the angle bracket using
screws and washers.
1
Attach screws, square nuts
and washers to the support
bracket before mounting. Slide the
square nuts of one support bracket
into the support beam T-slots.
Tighten the screws. Make sure that
the support bracket is aligned with
the beam.
1
Mount the angle bracket
to the transverse beam
in the same manner. Tighten all
screws.
2
Insert the square nuts of
the second support bracket
into the support beam T-slots. Slide
the bracket down so that it does
not protrude above the support
beam.
2
Insert the required
number of square nuts
into the structural beam T-Slot.
1
Use a soft hammer or
mallet to mount an end cap
on to the support beam.
3
Mount the connecting
plate using screws and
washers.
2
Mount the rst support
bracket to the conveyor
beam. Pull the second bracket
up and insert the T-bolts into the
conveyor beam T-slot. Tighten the
nuts.
4

qcconveyors.com | Assembly — Conveyor Beam Installation | 7
Drive Unit Installation Idler End Installation
End Unit Installation 
Conveyor Beam InstallationASSEMBLY 
Note: Assemble the entire conveyor beam structure in the same way. If the conveyor beam is too long to mount onto the support struc-
ture in one continuous length, assemble shorter lengths and connect them to each other once fastened to the suport beams.
The next step is to connect the straight sections, drive units, idler units and bends to each other. Connect all conveyor beams
according to instructions below.
Loosen the four set
screws that are inserted
into the drive unit connecting
strips. Insert the connecting strips
into the T-slot of the beam you
want attached to the drive unit.
Make sure the set screws do not
prevent the connecting strips from
sliding into place.
1
Make sure that the set
screws do not prevent
the connection strips
from sliding into place.
2
Insert the idler unit
connecting strips into
the T- slots of the beam end and
tighten it.
1
Connect two conveyor
beam ends by inserting
connecting strips into the
beam T-slots. Use two
connecting strips per beam
joint.
1
Tighten the set screws
using an Allen wrench.
2
Tighten the set screws
using an Allen wrench.
3
Tighten the set screws
using an Allen wrench.
2

8 | Install Slide Rail — Assembly | Flextrac Series
Install Slide Rail ASSEMBLY

Joining Slide Rail

Start the slide rail assembly
at an idler end unit.
Separate the top and bottom
ange of the slide rail at the end of
the rail and press into place.
1
Cut both slide rail ends at
45° angle. The beginning
of the new slide rail section in the
direction of travel should receive
a second cut at a slightly steeper
angle.
1
Ensure the slide rail is
properly mounted and
snaps onto the beam. The anged
edge of the siderail should snap
over the ange on the inner edge
of the beam.
2
Allow a space of
approximately 10mm
between two slide rail ends.
2
Use the slide rail assembly
tool to press the slide rail
into place. One end of the tool is
used when slide rail is mounted
onto rst side of the beam and the
other end is used when mounting
slide rail onto the second side.
3
Do not place two slide rail
joints opposite each other.
Make sure there is a distance of
at least 100mm between them to
make sure the chain run smoothly
(this does not apply at idler end or
drive unit; these joints are always
parallel).
3
Slide rail should be
installed on both top
and bottom of beam (unless top
running chain only).
4
The slide rail is attached to the sides of the conveyor beam to reduce chain friction where the chain would otherwise be in direct
contact with the beam prole. It is very important that the slide rail is installed properly, so that the chain can run without disruption.

qcconveyors.com | Assembly — Wheel Bend Slide Rail Installation | 9
Wheel Bend Slide Rail InstallationASSEMBLY 
Try to let the slide rail run in as many continuous lengths as possible, except in circumstances stated below:
• It is recommended to use short slide rail sections (approximately 2m to 3m) where chemicals may have an eect on the slide rail
composition.
• It is important to cut the slide rail and allow for elongation in high load areas. Cuts are required in wheel bends, by idler units and
where the conveyor will be heavily loaded, especially by drive units. This prevents the slide rail from expanding into the drive unit,
which may lock the chain.
• Never join slide rail in plain bends or vertical bends, since forces are higher on the slide rail in these sections. Instead, place the
joint before the bends.
• Avoid joining slide rail on top of conveyor beam joints.
Note: Diagram below shows cross-section of conveyor beam after slide rails are installed for dierent size of frames.
Cut the slide rail end at
45° angle on the inner
radius of the bend.
1Cut the slide rail at 45°
angle with a short back
cut. The slide rail must be longer
than the conveyor beam itself and
there should be a 2mm distance
between the slide rail and the
wheel.
3
The slide rail must be
longer than the conveyor
beam itself and there should be a
10mm gap between the slide rail
and the wheel. Ensure the end
of the slide rail is not bent up or
down.
2On the outer bend, make
sure that the slide rail is
properly connected to the conveyor
beam prole.
4

10 | Fixing Slide Rail Using Rivet — Assembly | Flextrac Series
Fixing Slide Rail Using Rivet ASSEMBLY

Drill two holes near the
beginning of each slide rail
section. Use the drill xture to ensure
clean-cut holes and correct location
of the holes. The holes must be at the
beginning edge of the joint piece, in
the direction of travel, to hold slide
rail in place when conveyor is in use.
Use a well-sharpened drill bit.
1Use a countersink to
deburr and countersink
the holes. Also ensure no metal
lings are left underneath the
slide rail.
2Insert rivets in the holes,
using rivet crimping tools
to crimp the rivets
3Check that rivets do not
protrude over surface
of slide rail. Check both top and
bottom surface of slide rail for
protruding metal.
4
Keep a distance of
approximately 30mm
between rivets and idler unit in
case the idler end must be removed
after conveyor system assembly.
5
Applicable for MS2 and MM3 only
MS2 SR 25 Slide Rail Shown


qcconveyors.com | Assembly — Fixing Side Rail Using Screw | 11
Fixing Side Rail Using Screw
ASSEMBLY 
Drill two holes near the
beginning of each slide rail
section. Use the drill xture to ensure
clean-cut holes and correct location
of holes. The holes must be at the
beginning edge of the joint piece, in
the direction of travel, to hold slide
rail in place when conveyor is in use.
Use a well-sharpened drill bit.
1Use a countersink to
deburr and countersink
the holes. Also make sure no metal
lings are left underneath the
slide rail.
2Insert screws in the holes,
using screw bit and hand
drill to tighten the screws.
3Check that screws do not
protrude over surface
of slide rail. Check both top and
bottom surface of slide rail for
protruding metal.
4
Keep a distance of
approximately 30mm
between rivets and idler unit in
case the idler end must be removed
after conveyor system assembly.
5
Applicable for ML2 and MX2 only
MS2 SR 25 Side Rail Shown


12 | Joining Chain Ends — Assembly | Flextrac Series
Joining Chain Ends ASSEMBLY

Check that the chain is
exible at the joint and
that the pin does not stick out or
protrude through the other side.
4
Line the Flextrac Series
chain tool up with the
pin. Slowly depress the trigger
until the pin seats.
3
Insert the steel pin
halfway, using a pair of
pliers. Always use new steel pins
and plastic pivots when joining
chain ends.
2
Insert the plastic pivot
with the slot facing
outward.
1
Length Adjustment of the Conveyor Chain

Stretch the chain and
remove links if necessary
so that the chain exhibits some
slack at the drive unit. Connect the
chain ends.
4
Join the chain ends. 3 Feed the chain along the
conveyor by pulling it
through the idler unit and back to
the drive unit
2
Insert the chain into the
underside of the drive
unit. Ensure the chain will be
moving in the correct direction, as
indicated by the arrow located at
the side of all chain links.
1
1. Adjustment of the conveyor chain is carried out at the drive end of the conveyor.
2. Remove the chain catenary protection plate.
3. The conveyor chain should be tensioned within the conveyor system by pulling down the conveyor chain at the chain catenary
in the underside of the drive unit. Clamp across the conveyor chain to trap the chain on the beam prole. The clamp should be
placed over the edges of the drive unit to reduce the risk of damage to the aluminium prole.
4. Remove all slack links from the conveyor chain using chain insertion tool.
5. Rejoin the conveyor chain using a new steel pin and plastic pivot.
6. Remove the chain clamp and replace the catenary protection plate.
Installing Chain


qcconveyors.com | Assembly — Conveyor Guide System | 13
Conveyor Guide System
ASSEMBLY 
Guide rails are used to guide products being conveyed, but also to prevent them from falling o the conveyor.
Guide rails are supported by guide rail brackets attached to the sides of the conveyor beam. Follow the mounting instructions for the
type of bracket used in your application.
Brackets should be placed approximately 500 to 1000 mm apart depending on type of product and if accumulation occurs or not. If
brackets are spaced at greater distances than 1000 mm, there is a possibility that guide rails will become deformed due to excessive
force.
Mounting Guide Rail Bracket (Aluminum Distance Tube) 
Insert square nut into
T-slot of the beam. Insert
set screw to the square nut.
1Attach the guide rail
bracket to the distance
tube. Tighten the screw.
Attach the guide rail to the guide
rail support. Tighten the screw.
3
Tighten the distance tube
to the set screw.
2Dierent distance tubes
are available to increase
side guide width.
4
Mounting Guide Rail Bracket (Polyamide) 
Insert square nut into
T-slot of the beam. Fasten
a guide rail bracket using hex head
screw and washer.
1Attach the guide rail to
the guide rail support.
Tighten the screw.
3
Attach a guide rail tube
and guide rail support
to the bracket. Tighten the nut or
hand knob.
2
Note: Spacers can be added to increase side guide width. Use long bolt when mounting the bracket support and distance spacer to the
conveyor beam. The length of the bolt depends on the number of spacers added.

14 | Connecting Guide Rail — Assembly | Flextrac Series
Connecting Guide Rail
Mounting Guide Rail Cover
ASSEMBLY


Connecting sleeves are
fastened to the guide rail
ends with set screws and an Allen
wrench. Make sure you place the
connecting sleeves on the outer
side of the guide rail.
1
To prevent products from
being scratched, a plastic
guide rail cover can be snapped
onto the inside of the guide rail.
1Make sure that all cover
joints are smooth, so
that products do not get caught or
damaged. Do not join covers on top
of guide rail joints.
2

qcconveyors.com | Assembly — Bending Guide Rail | 15
Bending Guide RailASSEMBLY


To calculate the length of guide rail to be bent, use formula below:
L = ( 2π x r x α ) / 360
Where, L = length of bend, r = radius, α = bend angle
If multiple bends with the same radius are to be made, note the nal position of the upper wheel is indicated to make sure correct radius
of subsequent rails. It is possible to bend angles up to 180°, minimum radius is 100mm.
Operate the crank to run
the rail back and forth
while lowering the upper wheel
step by step until the desired radius
and angle is achieved.
3
Mark the length of the
rail to be bent. Leave an
approximately 200mm straight
section at each end.
1Place the rail horizontally
between the top wheel
and the lower wheels. When
bending guide rail, you should
start bending from the center of
the required radius.
2

16 | Mounting Conveyor Beam Support Brackets — Assembly | Flextrac Series
Mounting Conveyor Beam Support Brackets ASSEMBLY

Assembling Conveyor Beams

Connect two conveyor
beam ends by inserting
connecting strips into the beam
T-slots. Use two connecting strips
per beam joint.
1Make sure that the set
screws do not prevent the
connection from sliding into place.
2Tighten the set screws
using Allen wrench.
3
Insert end cap on both
sides of the beam using a
soft hammer.
1Place the support bracket
in place. Do not tighten
the screws.
2Mount the rst support
bracket to the conveyor
beam. Pull the second bracket up
and mount the second support
bracket to the conveyor beam.
Tighten the screws.
3

qcconveyors.com | Plastic Belt Installation — Mounting Drive Units | 17
Mounting Drive Units
Mounting Idler Ends
PLASTIC BELT INSTALLATION



Note: Drive units should be mounted with a support leg as shown below.
Loosen set screws
included in drive unit
connecting strips. Insert the
connecting strips into the T-slots
of the beam you want to attach
to the drive unit. Make sure that
the set screws do not prevent the
connecting strips from sliding into
place.
1
Insert the idler unit
connecting strips into the
T-slot of the beam end.
1
Tighten the set screws
using an Allen wrench.
2
Secure the idler end to
the beam using an Allen
wrench to tighten the set screws.
2
This section shows the method to mount drive units to the frame structure. All
drives come with connecting strips. Attach them to the conveyor beam using an
Allen wrench and the set screws that are included.
Remember!
Conveyor belt should always be pulled, not pushed, by the drive unit.
This section shows the method to mount idler ends to the frame structure. All
idlers come with connecting strips. Attach them to the conveyor beam using an
Allen wrench and the set screws that are included.

18 | Safety Considerations — Start-Up and Testing | Flextrac Series
Locate hazardous area out of reach of the personnel involved
Use guards, or mechanical barriers, preventing entry into the hazardous area or protecting against falling goods.
Control devices should prevent or interrupt hazardous conditions
Use warnings instructions, sounds or light signals to alert of hazardous conditions
Warnings shall be used when other means of safeguarding will impair the function of the installation
To eliminate the risk of accidents, it is important to be aware of certain areas of the conveyor where special caution is required during
installation, operation and maintenance. Some areas present a higher danger to personal safety and because of this various kinds of
safety devices must be installed.
All pinch and shear points as well as other exposed moving parts that present a hazard to employees at their workstations or
their passage ways must be safeguarded.
Cleated conveyor chains are more susceptible to creating pinch and shear points than plain chain.
When two or more pieces of equipment are interfaced, special attention must be given to the interfaced area to ensure proper
safeguarding.
For overhead equipment, guards must be provided if product may fall o the equipment for some reason. The same applies to
all incline, decline and vertical conveyors.
Safety Considerations
Safeguarding
STARTUP AND TESTING



qcconveyors.com | Start-Up and Testing — Start-Up | 19
Start-Up  STARTUP AND TESTING
Lubrication
The conveyor chain is lubrication free. However, for some specic applications where the operating environment is particularly
hostile, regular lubrication of the slide rail/conveyor chain will result in a lower coecient of friction, longer life and reduced running
cost. Use a silicon-based lubricant.
Wear
The amount of wear on a conveyor depends on a number of factors, such as:
Chemicals
Contamination
Temperature
Plain bends
Running time
Load, contact pressure
Speed
Product accumulation
Sharp or rough products
Try to minimize the running time for the conveyor by stopping it when there is nothing to transport. Multiple horizontal and vertical
plain bends in a conveyor will often result in increased wear. One reason is that the friction losses are large in plain bends. Also, the
contact surface between chain and slide rail is small and the chain pull is acting towards the slide rail in the bends.
Break-in Period
Two or three days are recommended as a break-in period. During this time, the conveyor should be removed and cleaned two to
three times to remove dust. Use warm water (around 120° F), using soap if necessary. After cleaning, re-install the chain. After break-
in period wear will be minimized unless particles from product or process reach the conveyor continuously.
Chain Elongation
During the break-in period, regular checks should be made for elongation of the conveyor chain. This is especially important if the
conveyor is transporting high loads or is of long overall length. Regular inspections of the chain elongation are important. The chain
should be shortened after rst 40 hours of running time.

20 | General — Introduction to Maintenance | Flextrac Series
General INTRODUCTION TO MAINTENANCE

This maintenance manual allows the users to maintain the conveyor in a manner which will ensure safe maintenance, smooth
operation and maximum life span of the system. Please read and understand this manual before operation or performing
maintenance on the system. Documentation may not be reproduced in any form without the written permission of the manufacturer.
DO NOT ATTEMPT MAINTENANCE ON ANY CONVEYOR
WHILE IT IS IN OPERATION
 